Additive Manufacturing & Allied Technologies

K.P. Karunakaran Professor, Mechanical Engineering Coordinator, Rapid Manufacturing Laboratory

IIT Bombay

Outline
Principle of AM Three Considerations in Selection of AM Technology

AM Research in IIT Bombay

Benefits & Applications Significant Benefits & Applications Allied Technologies (pre-/in-situ/post-build) Rapid Manufacturing = AM + Allied Technologies

Three Levels of RM
Conclusions

Principle
How to make things faster?
The goal is to speed up the design, evaluation and manufacturing cycles. Human involvement is the bottleneck to speed. Therefore, eliminate or at least minimize it through automation. The two parts of automation are: i. Automation of process:
(a) Hard automation (automats, SPMs, transfer lines) (b) Soft automation (CNC machine, robot, AGV, AS&RS, FMS)

ii. Automation of process planning (CAPP):

(a) CAPP for subtractive processes: Failure except axi-sym., prismatic and some 3-axis (b) CAPP for additive processes: RP

When both are automated, we shall refer it as Total Automation

Principle
Sign Change in Manufacturing: Minus to Plus
- +: Till 1987, manufacturing was dominated by material subtraction - not only in machining but also in the formative processes such as casting and forging. The sign change in manufacturing with the advent of Additive Manufacturing by 3D Systems led to total automation in converting art-to-part (design-tomanufacturing or virtual-to-physical). So, it is faster and hence called Rapid Prototyping. CNC machine It is as easy and simple as 2D printing. So, many prefer to call it as 3D Printing. AM machine

Principle
Analogy with printing

Principle
Analogy with printing

Totally automated 2D printing (Lithography)

Totally automated 3D printing (Stereo-lithography)

AM revolutionized the way products are designed and manufactured today. It is an effective tool to compress product development time and hence gives an edge over the competitors.

Principle
Definition
AM is an automatic process of manufacturing objects (parts, prototypes, tools and even assemblies) directly from their CAD models without any cutters, tools or fixtures specific to the object geometry.

V01-Mono - DICO ZPrinter Processing

Principle
Stay Together (for cows);

Divide and Conquer (for lion)

Once upon a time there lived four cows in the forest. Every day they used to graze together in a particular spot. They were all friends. One day a lion saw the cows grazing together.

The lion wanted to eat them. So he went to attack one of them. But all the cows joined together and fought with him. The lion had to run away.

A few days passed and the cows quarreled among themselves and started grazing separately. The lion killed and ate them all one by one.

Principle
Need for support mechanism

Scaffolding for a water tank

V02-Materialises Mommonth SLA

Principle
Popular AM processes
3DP SLS SLA
Powder-bed tech.; No laser, just a liquid binder, hence cheap, all materials. ZCorp: Starch; FGM (color); SoliGen: Ceramic; FGM; ProMetal: Metal; FGM Powder-bed tech.; Laser, hence costly but faster and accurate, all materials. 3D Systems: Single machine; EoS: 3 different machines; Many clones Liquid-bed tech.; Laser, hence costly but faster and accurate, photopolymer. 3D Systems; Many clones; other photo-polmer sys: SGC, Envisiontec, Objet

FDM

Extrusion of thermoplastics; No laser, hence cheap but slow and less accurate. Stratasys (www.stratasys.com)
Joining profiled laminates; not sophisticated laser, hence cheap. Fast. Cubic (www.cubic.com)/ SolidDimensions

LOM

Principle
Popular AM processes - Videos
3DP SLS SLA
V01-Mono - DICO ZPrinter Processing V03a-EoS-Sand-SLS-in ACTech V03b-EoS-DMLS V02-Materialises Mommonth SLA

FDM

V04-FDM process V05-LOM

LOM

Principle
Geometric Input to 3DP/RP: STL format

The greatness of this man lies in his simplicity! Gandhi and Ganapathy dont complain!!

Coarse resolution

Fine resolution

Principle
Geometric Input to 3DP/RP: STL format
solid AutoCAD facet normal 0.0000000e+000 outer loop vertex 1.0000000e+001 vertex 1.0000000e+001 vertex 0.0000000e+000 endloop endfacet facet normal 1.0000000e+000 outer loop vertex 1.0000000e+001 vertex 1.0000000e+001 vertex 1.0000000e+001 endloop endfacet endsolid AutoCAD 0.0000000e+000 1.0000000e+000 0.0000000e+000 1.0000000e+001 1.0000000e+001 1.0000000e+001 1.0000000e+001 1.0000000e+001

0.0000000e+000 0.0000000e+000 0.0000000e+000 0.0000000e+000 1.0000000e+001 0.0000000e+000 1.0000000e+001 1.0000000e+001

Consideration in the Selection of RP

1 2 Min. layer thickness Quality requirement influencing geometry (accuracy and surface finish) 3 Support mechanism Quality requirement influencing surface finish of undercut regions Requirement influencing (a) additional material, (b) time, (c) cost, (d) feasibility of manufacture

Material Quality requirement influencing strength, weight, life, transparency etc.

Solid-powder: High material variety; simple support mech. Solid-sheets: High material variety; Fast; ease of handling; material wastage Solid-wire: Ease of feeding; high material variety and utilization Liquid: Excellent accuracy; transparency; Complex support mech. Gas: Not yet but why not!

AM Research in IIT Bombay

Hybrid Layered Manufacturing (HLM)
3-axis HLM MIGTIGLaser

5-axis HLM

Multiple torches

AM Research in IIT Bombay

Capabilities of HLM
3-Axis HLM 5-Axis HLM (Positional) 5-Axis HLM (Continuous)

Monolithic dies

Composite Dies with conformal cooling

Impeller

Components without undercuts

Components with several 3Videos: axis features in different V06a 5-ax deposition orientations
Components with undercuts

V06b 5-ax machining

Blisks

AM Research in IIT Bombay

Comparison of 5-axis MIG-HLM with Aeromets LAM
CAD Model Boeings Ti Part Built Using LAM Near-net Shape Final Shape

Al Impeller Built Using HLM

AM Research in IIT Bombay

Huge polystyrene prototyping: Seg. Obj. Mfg. (SOM)

V07-SOM

Benefits & Applications

Benefits & Applications

AM for Common Public (June 2013!)

Benefits & Applications

High Bandwidth Communication Tool: Gas Turbine
Rs. 19,80,000 (30,000 Euro )

3 Weeks (Timebound delivery through extensive outsourcing)

High bandwidth communication tools 1:1 working model (1.1m long)
V08-GTRE Engine

Benefits & Applications

Many design iterations within limited time

Design iterations improve quality of design. But they also consume resources. Never evaluate an idea at the time of brainstorming. Never fall in love with your own ideas; this will block newer ideas

Benefits & Applications

Various applications
Concept models for better visualization (high bandwidth communication tool) Models to check the aesthetic appeal; also for market survey. Models for form, fit and functional tests
Models for stress analysis using photo-elasticity Models for wind tunnel tests Models for design review

RP models can be sent along with the inquiries; RP models can be submitted along with the quotations. Medical applications in conjunction with VR, AR & RE. RP also has its applications in micro/nano-applications. RP is emerging into Rapid Manufacturing.

Assemblies can be made without joints. It can make parts impossible by other manufacturing methods.

Essentially RP cuts down product development time and RT cuts down productionizing time. With an integrated approach, RP, RT & RM can shorten time to market.

Benefits & Applications

Photo-elasticity models, working prototypes, patterns

Concept model

Transparent models for photo-elasticity studies

Material translation through Investment Casting

Fully functional prototypes

Benefits & Applications

Medical (models, prosthetics & implants); micro-RP

MEMS [MicroTek, Germany]

Medical applications: Reverse Engineering, Virtual Reality, Augmented Reality, RP and RT have far reaching implications in medicine!

0.9 OD; 0.4 ID; 0.05m

Significant Benefits & Applications Features difficult/impossible by other means

Design used to be constrained by the manufacturing limitations in the past. Additive Manufacturing has made the following possible giving designers greater freedom:
1. Conformal cooling channels 2. Assemblies without joints 4. Non-equilibrium Objects

3. Gradient Materials

5. Difficult or Impossible Shapes 6. Customized solutions

So, design innovation need not be limited by the manufacturing constraints. It should exploit these newer capabilities.

Benefits & Applications

1. Conformal cooling channels

Cycle time reduction Less distortion Good integrity

Benefits & Applications

2. Assemblies without joints

Courtesy: EoS, Germany Thin walled turbine combustion chamber, produced on EOSINT M 270, material EOS Nickel Alloy IN 718. Courtesy: Materialise Solutions, U.K.

Courtesy: Stratasys, USA

Benefits & Applications

3. Gradient Materials; 4. Non-equilibrium Materials

Courtesy: ZCorp, USA

Courtesy: Optomec, USA

Benefits & Applications

5. Difficult or complex shapes

Benefits & Applications

6. Customized solutions

Allied Technologies (Pre/In-situ/Post-Build)

Challenges in AM: Poor external quality
(i) Poor surface finish due to stair-step error (ii) Irregularities created during support removal

CAD model

AM part

When surface finish is very poor, tolerance cannot be better than that!

Allied Technologies (Pre/In-situ/Post-Build)

Challenges in AM: Poor internal quality
- Each RP process has a limited material composition, that too, in narrow band of properties
FDM Polymers (thermoplastics) SLA Photo-polymer SLS/3DP Good variety from polymer to metal but one machine for each. LOM Paper

- All RP materials are proprietary

- Due to open loop (absence of human) - Commercial reasons: Exorbitantly priced (40-60% of cost is material)

- Inherently anisotropic

Allied Technologies (Pre/In-situ/Post-Build)

Challenges in AM: Slow

MCP Realizer at LERMPSUTBM, Belfort

Matl: Ti64; Size: 83 x 68 x 131; layer thk. = 0.040 (1700); Time: 60 hrs. Stand in front of a CNC machine for 5 min (when it is working!) and then in from of a AM machine for 5 min. You will find out which is fast! That is why we do not call it RP any more!!

Allied Technologies (Pre/In-situ/Post-Build)

Challenges in AM: Linearity of cost & time
All AM materials are proprietary and exorbitantly priced (4060%) Exorbitantly priced equipment in order to recover IP fast.

AM has linearity of cost (& time) with quantity.

RP

Indirect Processes

Allied Technologies (Pre/In-situ/Post-Build)

Challenges in AM: Summary
Quality i. Exterior or surface ii. Interior or matrix
- Surface finish

- Accuracy
- Composition - Limited range of each process - Proprietary - Homogeneity (inherent anisotropy, porosity & residual stresses)

Cost

Linear!

Time

Time to build
Life

Not rapid enough! - Number of layers - Sacrificial support Low life due to - Poor quality - Degeneration over time

Allied Technologies (Pre/In-situ/Post-Build)

Challenges in AM: Summary
The usefulness of AM is amplified manifold by through appropriate pre/in-situ/post-build processes to overcome their limitations. Pre-build processes In-situ build processes
Reverse Engineering Model processing: Data reduction, splitting large pieces along with joints for gluing, editing models, repairing models, lattice structure Analysis and optimization (OptiLOM) Embedding PCB, inserts etc. Cold working after every layer

Post-build processes
Improving surface quality (polishing, machining) Improving interior quality (Thermal and/or pressure treatments) Multiple pieces and/or of desired material through indirect routes (vacuum casting, metal casting)

Machining in-between a certain number of layers

Additive Manufacturing + Allied Technologies = Rapid Manufacturing

Allied Technologies (Pre/In-situ/Post-Build)

Exterior improvements: Liquid polishing
Micro-Machining of BestinClass, Swiss

Allied Technologies (Pre/In-situ/Post-Build)

Interior improvements: Hot Iso-static Pressing (HIP)
Powder-based RP (laser/EB sintering or bonding) is not strictly PM as compacting is missing. Powder-based metallic AM processes invariably have some microporosities which reduce their fatigue life required in aerospace. HIP makes them as strong as machined or forged components.

Allied Technologies (Pre/In-situ/Post-Build)

Interior improvements: Hot Iso-static Pressing (HIP)
Leak proof joints and valves are critical in HIP. This was a restricted technology a few years ago. Very recently, ASACO, Secundarabad, started offering these machines. Three of their machines are in India:
DMRL VSSC TVS Job size Max pressure 650mm dia x 1200mm long 2000 bar 500mm dia x 1000mm long 2000 bar Small (for the casing of 2000 bar turbo-charger)) Max temp. 1440C/ 2000C 1440C 1440C

It costs around Rs. 30 crore.

Allied Technologies (Pre/In-situ/Post-Build)

Indirect Processes: Investment Casting (QuickCast)
3D Systems SLA mchine produces quasi-hollow patterns. Note that:
the honeycomb structure is achieved using QuickCast build style and no special geometric pre-processing is required. Hollowness is not for saving material or speed but to avoid shell cracking.

Courtesy: Mercedes-Benz

QuickCast uses flask investment casting. Of late, SLSs dense polystyrene patterns are replacing this.

Courtesy: Bajaj Auto, India

Knee implant

Allied Technologies (Pre/In-situ/Post-Build)

Indirect Processes: Investment Casting

Magnesium Seal housing of Kaveri engine (GTRE, Bangalore) made by Aerocast, France

Allied Technologies (Pre/In-situ/Post-Build)

Indirect Processes: Investment Casting

Indigenous Efforts in Rapid Casting (Aluminium)

GTRE, Bangalore, IIT Bombay, CTR, Ludhiana and PTC, Lucknow

Allied Technologies (Pre/In-situ/Post-Build)

Indirect Processes: Investment Casting

Allied Technologies (Pre/In-situ/Post-Build)

Indirect Processes: Investment Casting
Slurry coating

Ice

Pressure & Temp. Controlled Environment (Controlled Vacuum Freezer)

Allied Technologies (Pre/In-situ/Post-Build)

Indirect Processes: Sand casting without pattern

Rapid Manufacturing (RM)

RM = AM + Allied Technologies
Metallic RM

Direct Routes

Matl. SRM LM Best Ok Ok Best

Geom. Best Ok Best Ok Without Patterns

Indirect Routes

Subtractive

Additive

HLM RC

Rapid Casting

CNC Machining

Laminated Manufacturing

Powder-bed Technologies

Deposition Technologies

With Patterns

3
Bonding Sintering Fusion Additive Subtractive NonConsumable Consumable

Laser

EB

Arc

Hybrid

Unlike the layered mfg approach of RP, RM would require multi-faceted and hybrid approaches to meet the varied needs of material, quality, quantity, cost etc.

Three levels of RM
Characteristics Name Price Materials Technologies Purpose L1
3D Printing < Rs. 500,000 ($ 10,000) Limited to one polymer Only AM Only visualization

L2
RM for polymers < Rs. 5,000,000 ($ 100,000) A variety of polymers AM and Indirect (Vac. Casting etc.)

L3
RM for polymers, metals and ceramics > Rs. 50,000,000 ($ 1,000,000) A variety of polymers, ceramics and metals AM & indirect (Rapid Casting, HIP etc.)

Functional; need not Functional; need not be limited to prototype be limited to prototype

Location

In-house; preferably in every design office like a 2D printer.

The same organization will require more than one technology. Load will not be enough to justify in-house facilities. So outsourcing is preferred except for one or two essential ones.

Conclusions
The divide & conquer approach of Additive Manufacturing (AM) led to total automation. This revolutionized the way products are designed and manufactured today. The same divide & conquer approach is responsible for the pathetic quality, short life, long production time and high cost. These bottlenecks can be overcome by adopting appropriate allied technologies which are pre-/in-situ/post-build processes. These together are known as Rapid Manufacturing (RM). We need to adopt HYBRID approaches for immediate and near future needs. They may be [addition, subtraction], [bonding, fusing], [Arc, Laser, EB], [2.5 ax, 3-ax, 5-ax], [Direct, Indiect]

Conclusions
The special geometric and material features of RM gives greater design freedom which are yet to be exploited. RM exists for any situation. So (a) their appropriate selection and (b) Design for RM are essential for efficient product development.

Thank You!
K.P. Karunakaran Professor Department of Mechanical Engineering Indian Institute of Technology Bombay Powai, Mumbai-400076, INDIA Tel.: 022-25767530/ 9869541570 karuna@iitb.ac.in www.me.iitb.ac.in/~karuna

Coaxial Helicopter

Videos

Classification of AM Processes
1. Vat Photo-polymerization process SLA, Envisiontec DLP, MicroSLA 2. Material jetting process (single & multi nozzles) Objet 3. Binder jetting process 3DP (Zcorp, ExOne) 4. Material extrusion process FDM 5. Powder-bed fusion process

S(L/EB)S
6. Sheet lamination process LOM, UC

7. Directed Energy Deposition process

FDM

Classification of AM Processes

AM Research in IIT Bombay

Research Interests
Tail-less Heli (multi-rotor & Tipjet) RW MAV Rapid Casting & Large Prototyping Hybrid Layered Manufacturing (HLM) OptiLOM Optimization of Machining through Simulation (G) and Modeling (M)
1994 2000 2005 2010 2015

Nandi (Holy Cow of Isha)

Reverse Engineering + Jugadu (ingenuity)

Dim: 10 ' x 20' x 15'

Material: MS Weight : 22 Tons Project duration: 6-8 months Method used: 1/6th POP and WAX models. Scanned using Handyscan. Built through jugadu.